Structural member and method of making same

ABSTRACT

A structural member includes a coil shaped member having a coil radius measured from a center line, and coil length measured along the center line. A plurality of stiffener plates having opposing faces and opposing side edges are connected to points along the length of the coil shaped member, wherein the plurality of stiffener plates stabilize the coil shaped member and increases the bearing capacity of the structural member. Each stiffener plates has a length that is substantially the same as the coil length, and only on side of each stiffener plate is connected to the coil shaped member. The center line of the structural member may be straight or arcuate. Alternate embodiments may include additional coil shaped members.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates generally to a new structural member that may be used in construction or other applications.

[0003] 2. Description of the Prior Art

[0004] Turkish patent number 27716 discloses a structural member having spiral springs of various diameters stabilized with steel rods. While this design works well for smaller, lighter structures, the load bearing capability is insufficient for larger structures.

[0005] Therefore, there is a need for an improved structural member having increased load bearing capability, which may be used to make economical, stable, and aesthetically pleasing structures, such as arches, shells, trusses, and other decorative structures.

SUMMARY OF THE INVENTION

[0006] Generally, the structural member of the present invention can be used in constructing a broad range of structures. The structural member can be used as masts, for constructing domes, and to cover structures with very long spans.

[0007] A structural member includes a coil shaped member having a coil radius measured from a center line, and coil length measured along the center line. A plurality of stiffener plates having opposing faces and opposing side edges are connected to points along the length of the coil shaped member, wherein the plurality of stiffener plates stabilize the coil shaped member and increases the bearing capacity of the structural member. Each stiffener plates has a length that is substantially the same as the coil length, and only on side of each stiffener plate is connected to the coil member. The center line of the structural member may be straight or arcuate. Alternate embodiments may include additional coil shaped members.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which like numbers designate like parts, and in which:

[0009]FIG. 1 is a perspective view of the structural member in accordance with the present invention;

[0010]FIG. 2 is an end elevation view of the structural member shown in FIG. 1;

[0011]FIG. 3 is a perspective view of a second embodiment of the structural member of the present invention;

[0012]FIG. 4 is an end elevation view of the structural member shown in FIG. 3;

[0013]FIG. 5 is a perspective view of a third embodiment of a structural member in accordance with the present invention;

[0014]FIG. 6 is an end elevation view of the structural member shown in FIG. 5; 15

[0015]FIG. 7 is a perspective view of a fourth embodiment of the structural member in accordance with the present invention;

[0016]FIG. 8 is a end elevation view of the structural member shown in FIG. 7;

[0017]FIG. 9 is an alternate perspective view of the structural member shown in FIG. 7;

[0018]FIG. 10 is an end elevation view of a first coil shaped member used in the structural member shown in FIGS. 7 and 9;

[0019]FIG. 11 is a end elevation view of a second coil shaped member used in the structural member shown in FIGS. 7 and 9;

[0020]FIG. 12 is an elevation view of a structural member in accordance with the present invention used to construct an arch;

[0021]FIG. 13 is a partial view of the structural member used to make the arches shown in FIG. 12 and FIG. 14;

[0022]FIG. 14 is an elevation view of an arch-shaped truss using two of the structural members of the present invention;

[0023]FIG. 15 is an elevation view of a fifth embodiment of the structural member in accordance with the present invention;

[0024]FIG. 16 is an end elevation view, which shows an end flange of the structural member shown in FIG. 15;

[0025]FIG. 17 is a sectional view of a partially assembled structural member taken along line 17-17 in FIG. 15;

[0026]FIG. 18 is an elevation view of a completed structural member in accordance with the present invention; and

[0027]FIG. 19 is an end elevation view of the structural member shown in FIG. 18.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0028] Generally, spiral springs of various diameters, which are produced of round bars, are stabilized with stiffeners 30 of different dimensions. Spiral springs are welded where they touch the stiffeners (FIGS. 1 and 26).

[0029] As illustrated in FIG. 1, stiffeners or stiffener plates 30 are welded to spiral spring or coil shaped member 32 where inside edge 34 of stiffener plates 30 touches the coils. In the embodiment shown in FIG. 2, stiffeners 30 are welded to spiral spring 32 where outside edge 36 touches the coils. In FIG. 3, the bearing capacity is increased by using two different spiral springs 32 and 38 nested into each other. They are connected to each other by welding stiffeners 30 to these springs where inside edge 34 and outside edge 36 touch coil shaped members 32 and 38. A mast or structural member designed in this way is 75% lighter than other types of masts. This mast design is also economical.

[0030] The structural members of the present invention are used for producing economical, stable and aesthetic structures. For example, a structure having a span of 100 m can be easily covered with this system. And structures like arches, shells, trusses, and decorative structures can be easily constructed from these new structural members.

[0031] Different materials can be used when manufacturing the load-bearing spirals and stiffeners. For example, the system can be built from steel, aluminum, or iron.

[0032] Telescoping poles (see FIGS. 7-11) can be easily built by using a combination of an anterior-welded or exterior-welded spiral system (see FIGS. 1 and 2) together with an interior-welded system (see FIGS. 3 and 4). The exterior-and interior-welded spiral systems may be fixed with screw connections.

[0033] Prior art designs of steel arches, domes, and trusses used in the building industry are heavy and uneconomical. Also it is very difficult to build a prior art span over 80 m. However, using the method and structural member of the present invention will not only yield safe and stable structures, but economical structures too.

[0034] For example, let us consider the construction of an arch structure shown in FIGS. 12-14. Each module (see FIG. 13) can be about 5-6 m long to overcome transportation difficulties. However, this length restriction is not necessary if the transportation of longer units can be handled.

[0035] When designing the module mentioned above, first the dimensions of spiral spring 32 and stiffeners 30 are defined according to the structural and dynamic analysis of the system.

[0036] Once the dimensions of spiral spring 32 and stiffeners 30 are defined, the three stiffeners 30 of four are welded to end flanges 40 and to fasteners 42 between flanges, thus obtaining the skeleton 44 of the module (see FIGS. 15-17). After constructing skeleton 44 of the module, spiral spring 32 is located into skeleton 44 and then the touching places between spiral spring 32 and stiffeners 30 are welded. Finally, a fourth stiffener is welded to the spring to complete the module of the construction (see FIGS. 18 and 19, which shows the completed module.).

[0037] The foregoing description of a preferred embodiment of the invention has been presented for the purpose of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application, and to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled. 

What is claimed is:
 1. A structural member comprising: a coil shaped member having a coil radius measured from a center line and a coil length measured along the center line; and a plurality of stiffener plates having opposing faces and opposing side edges, wherein each stiffener plate has a length that is substantially the same as the coil length, wherein only one side edge of each stiffener plate is connected to points along the length of the coil shaped member, wherein the plurality of stiffener plates stabilize the coil shaped member and increases the bearing capacity of the structural member.
 2. The structural member according to claim 1 wherein the points along the length of the coil shaped member where the side edge of a selected stiffener plate is connected have a fixed radial angle with respect to the centerline.
 3. The structural member according to claim 1 wherein each side edge of each stiffener plate intersects a radial line extending perpendicularly from the centerline.
 4. The structural member according to claim 1 wherein the centerline is straight.
 5. The structural member according to claim 1 wherein the centerline is arcuate.
 6. The structural member according to claim 1 further including an end flange at a first end of the coil shaped member, wherein the end flange is connected to a first end of the coil shaped member and first ends of the plurality of stiffener plates, and wherein the end flange is centered on the center line.
 7. The structural member according to claim 6 wherein a plane of the end flange is perpendicular to the centerline.
 8. The structural member according to claim 6 further including a second end flange at a second end of the center line, wherein the end flange is connected to a second end of the coil shaped member and second ends of the plurality of stiffener plates, and wherein the end flange is centered on the center line.
 9. The structural member according to claim 1 wherein the one connected side edge of each stiffener plate is connected to points on the coil shaped member by a welded joint.
 10. The structural member according to claim 1 wherein the coil shaped member is produced from round bars.
 11. The structural member according to claim 1 wherein the opposing side edges of the stiffener plates include an inside edge closer to the center line and an outside edge further from the center line, and wherein the connections between each stiffener plate and points on the spiral shaped member are made on the inside edge of each stiffener plate, placing the stiffener plates outside the radius of the coil shaped member.
 12. The structural member according to claim 1 wherein the opposing side edges of the stiffener plates include an inside edge closer to the center line and an outside edge further from the center line, and wherein the connections between each stiffener plate and points on the spiral shaped member are made on the outside edge of each stiffener plate, placing the stiffener plates inside the radius of the coil shaped member.
 13. The structural member according to claim 11 further including: a second coil shaped member having a second coil radius measured from the centerline that is smaller than the coil radius, and having a second coil length substantially equal to the coil length, wherein the coils of the second coil shaped member are connected to the inside edges of the plurality of stiffener plates.
 14. The structural member according to claim 11 further including: a second coil shaped member having a second coil radius measured from a second centerline that is substantially equal to the coil radius, and having a second coil length measured along the second center line, wherein the coils of the coil shaped member and the second coil shaped member are spaced apart to form a double helix where the center line and the second center line partially coincide; a plurality of inner stiffener plates connected to the second coil shaped member, wherein the plurality of inner stiffener plates each have inside and outside edges, wherein connections between each inner stiffener plate and points on the second spiral shaped member are made on the outside edge of each inner stiffener plate, placing the inner stiffener plates inside the radius of the coil shaped member and the second coil shaped member, wherein the inside and outside edges of the plurality of inner stiffener plates intersect a radial line extending perpendicularly from the second centerline.
 15. The structural member according to claim 14 wherein the coil shaped member and the second coil shaped member are fixed in relation to one another.
 16. The structural member according to claim 14 wherein each of the plurality of stiffener plates is coplanar with one of the inner stiffener plates.
 17. The structural member according to claim 1 wherein the coil shaped member and the plurality of stiffener plates are made from a material selected from the group consisting of steel, aluminum, and iron.
 18. The structural member according to claim 2 further including a second structural member according to claim 2 having a second end flange, wherein the end flange and the second end flange are coupled together.
 19. A method of assembling a structural member comprising the steps of: positioning first, second, and third stiffener plates at a radial distance from a center line of the structural member, wherein each stiffener plate has opposing faces and opposing side edges, and wherein each stiffener plate runs the length of the center line, and wherein both opposing side edges of each stiffener plate intersect a radial line extending from the center line, and wherein the first, second, and third stiffener plates are distributed at different angles over a radial arc, centered at the center line, of no more than 180 degrees; welding end flanges to end edges of the first, second, and third stiffener plates, wherein an end flange is welded at each end of the group of first, second, and third stiffener plates; positioning a coil shaped member in contact with edges of the first, second, and third stiffener plates, wherein the coil shaped member has a radius measured from the center line that is substantially equal to the radial distance; positioning a fourth stiffener plate in contact with the coil shaped member at the radial distance from the center line, wherein the fourth stiffener plate runs the length of the center line, and wherein both opposing edges of the fourth stiffener plate intersects a radial line extending from the center line, and wherein the first, second, third, and fourth stiffener plates are located at different angles over a radial arc, centered at the center line, of more than 180 degrees; welding the points of contact between the edges of the first, second, third, and fourth stiffener plates and the coil shaped member; and welding end edges of the fourth stiffener plate to the end flanges.
 20. The method of assembling a structural member according to claim 19 wherein the first, second, and third stiffener plates each include an inside and an outside edge, and further including the steps of; welding a first fastener plate between the outside edge of the first stiffener plate and the outside edge of the second stiffener plate, wherein the first fastener is substantially perpendicular to the outside edges of the first and second stiffener plates; and welding a second fastener plate between the outside edge of the second stiffener plate and the outside edge of the third stiffener plate, wherein the second fastener is substantially perpendicular to the outside edges of the second and third stiffener plates.
 21. The method of assembling a structural member according to claim 19 wherein the centerline is straight.
 22. The method of assembling a structural member according to claim 19 wherein the centerline is arcuate. 